Graphic Rapper Controller™ (GRC) User`s Guide

Transcription

__________________
Graphic Rapper Controller™ (GRC)
User’s Guide
Rev. 3.1
Revisions
Rev.
1.0
1.1
2.0
2.1
2.2
3.0
3.1
Date
11/2/99
8/10/05
1/13/06
5/25/10
5/17/11
3/13/14
7/9/14
Author
FGS
FGS
RAZ
FGS
FGS
Description
Original
Added multiple rap feature
Updated for new display screens
Added board changing procedure to Troubleshooting section
Added 240V Migi Device Type
Added DSP SCPU feature
Updated Datamap & Local/Remote Control
NWL ENVIRONMENTAL TECHNOLOGIES
Copyright, warranty conditions
This user’s guide is fully protected by copyright. For easy
reference, we encourage you to photocopy any pages of this
manual that will be helpful in running the Graphic Rapper
Controller™ (GRC) and post them near the GRC. However,
you may not reproduce the manual for any other use, store it in a
retrieval system, or transmit it in anyway without the prior
approval of NWL Environmental Technologies.
This manual is supplied for the Convenience of GRC users. We
have tried to make it as comprehensive and error-free as
possible, but we assume no responsibility or liability for any
errors or inaccuracies that may appear in it. We also reserve the
right to improve it or otherwise change its contents without
notice.
Graphic Rapper Controller, ESP Power Optimizer, Rip/Rap,
and PCAMS/NT are trademarks or service marks of NWL
Environmental Technologies.
Written and designed at:
NWL Environmental Technologies
312 Rising Sun Road
Bordentown, NJ 08505 U.S.A.
1-800-742-5695 • 1-609-298-7300
FAX: 1-609-298-8235
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Table of Contents
Page ii
Table of Contents
TABLE OF CONTENTS .................................................................................................................................................... 1
TABLE OF FIGURES......................................................................................................................................................... 3
CHAPTER 1: INTRODUCTION ....................................................................................................................................... 4
NWL’S GRAPHIC RAPPER CONTROLLER............................................................................................................................ 4
UNIQUE “SMART SYSTEM” FEATURES ............................................................................................................................... 6
R-Scan .......................................................................................................................................................................... 6
Opacity Spike Detection ............................................................................................................................................... 6
Support for Over 1000 Devices .................................................................................................................................... 6
Auto-Lift Calibration.................................................................................................................................................... 7
System Redundancy ...................................................................................................................................................... 7
Automatic Program Selection ...................................................................................................................................... 7
High Resolution, 16 Line x 40 Character Display ....................................................................................................... 8
Opacity and Boiler Load Graphical Trending ............................................................................................................. 8
NWL’s Last ½ Cycle Variation..................................................................................................................................... 8
NWL’s Patented Ramped Intensity Pulsing – “Rip/Rap” ............................................................................................ 9
DOCUMENT STANDARDS ................................................................................................................................................. 10
TECHNICAL SUPPORT ....................................................................................................................................................... 10
HOW TO USE THIS MANUAL ............................................................................................................................................ 11
CHAPTER 2: QUICK START GUIDE ........................................................................................................................... 12
SMART-CPU CONFIGURATION ......................................................................................................................................... 12
SMART-RAP CONFIGURATION (EACH MODULE)................................................................................................................ 12
CHAPTER 3: USER INTERFACE.................................................................................................................................. 13
USING THE HAND-HELD PROGRAMMER ............................................................................................................... 13
KEYPAD ............................................................................................................................................................................ 13
Menu Bars .................................................................................................................................................................. 14
Data Section ............................................................................................................................................................... 14
Status Lines ................................................................................................................................................................ 14
On-Line Help ............................................................................................................................................................. 15
Signing On ................................................................................................................................................................. 15
MONITORING ................................................................................................................................................................... 16
Rapper Activity........................................................................................................................................................... 16
Operating Programs .................................................................................................................................................. 17
Anti-Coincidence Buffers ........................................................................................................................................... 19
Alarms ........................................................................................................................................................................ 20
B) OVERCURRENT, UNDERCURRENT, OR HALF-WAVE OCCURED.................................................................................... 20
Trending ..................................................................................................................................................................... 22
Opacity Spike Detection ............................................................................................................................................. 23
CONFIGURATION .............................................................................................................................................................. 24
Smart-CPU ................................................................................................................................................................. 24
Optional Fieldbus Converter ..................................................................................................................................... 29
SD-Card ..................................................................................................................................................................... 33
Smart-Rap .................................................................................................................................................................. 34
Rapper Setup .............................................................................................................................................................. 35
Hand-Held Programmer ............................................................................................................................................ 36
Power Feeds............................................................................................................................................................... 38
Operating Programs .................................................................................................................................................. 38
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Introduction
Page 1
Rapper Sequence ........................................................................................................................................................ 42
Program Timing Check .............................................................................................................................................. 44
Program Load ............................................................................................................................................................ 44
Program Save............................................................................................................................................................. 45
Operating Program Example ..................................................................................................................................... 46
ACG Affect on Program ............................................................................................................................................. 48
POR Affect on Program ............................................................................................................................................. 49
Selecting an Operating Program ............................................................................................................................... 51
Auto-Program Select .................................................................................................................................................. 52
Power Off Rapping..................................................................................................................................................... 53
Anti-Coincidence Grouping ....................................................................................................................................... 57
CHAPTER 5: TROUBLESHOOTING ........................................................................................................................... 59
INITIATE R-SCAN ........................................................................................................................................................... 59
OPACITY SPIKE DETECTION ............................................................................................................................................. 60
REPEAT DEVICE(S) .......................................................................................................................................................... 61
SMART SYSTEM PROFILE ................................................................................................................................................. 64
CALIBRATION................................................................................................................................................................... 65
CHANGING BOARDS ......................................................................................................................................................... 67
CHAPTER 6: CONFIGURATION SUMMARY............................................................................................................ 70
SMART-CPU .................................................................................................................................................................... 70
Board Address ............................................................................................................................................................ 71
SMART-RAP ..................................................................................................................................................................... 72
Board Address and Rapper outputs range ................................................................................................................. 73
Lift Table Select ......................................................................................................................................................... 75
Switch Setting ............................................................................................................................................................. 75
Lift Table .................................................................................................................................................................... 75
Stand-Alone Operation .............................................................................................................................................. 75
Device Type ................................................................................................................................................................ 76
Gain Switch ................................................................................................................................................................ 77
Gain ........................................................................................................................................................................... 77
How to set .................................................................................................................................................................. 77
System Installation Notes ........................................................................................................................................... 78
GLOSSARY OF TERMS.................................................................................................................................................. 79
APPENDIX 1 – FIELDBUS DATA EXCHANGE MAP ................................................................................................ 81
APPENDIX 2 – FIELDBUS MODULE ADDITIONAL INFORMATION .................................................................. 85
APPENDIX 3 – DSP BOARD FOUR CHARACTER LED DISPLAY MESSAGES .................................................. 89
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Introduction
Page 2
Table of Figures
Figure 1 - GRC Block Diagram ..............................................................................................................5
Figure 2 - HHP Keypad.........................................................................................................................13
Figure 3 - HHP Menu Bars ...................................................................................................................14
Figure 4 - HHP Data Section ................................................................................................................14
Figure 5 - HHP Status Lines .................................................................................................................14
Figure 6 - On-Line Help Window .........................................................................................................15
Figure 7 - Sign On Window ..................................................................................................................15
Figure 8 - Monitor Window ..................................................................................................................16
Figure 9 - Program Status Window.......................................................................................................17
Figure 10 - Anti-Coincidence Buffer Window .....................................................................................19
Figure 11 - Status Line Alarm Notification ..........................................................................................20
Figure 12 – S-RAP Alarm Summary screen .........................................................................................21
Figure 13 - S-RAP Alarms screen.........................................................................................................21
Figure 14 - Opacity and Boiler Load Trend Window ...........................................................................22
Figure 15 - Opacity Spike Detect Window ...........................................................................................23
Figure 16 - Smart-CPU Window ..........................................................................................................24
Figure 17 – Sub-Menu Window ...........................................................................................................29
Figure 18 – Ethernet I/P Configuration Window ..................................................................................30
Figure 19 – Profinet Configuration Window ........................................................................................30
Figure 20 – DeviceNet Configuration Window ....................................................................................30
Figure 21 – Modbus RTU Configuration Window ...............................................................................31
Figure 22 – Profibus Configuration Window .......................................................................................31
Figure 23 – SD Card Location ..............................................................................................................33
Figure 24 – SD-Card Function Window ...............................................................................................33
Figure 25 - Smart-Rap Window ............................................................................................................34
Figure 26 - Rapper Setup Window .......................................................................................................35
Figure 27 - Setup Window ....................................................................................................................37
Figure 28 - Power Feed Window ..........................................................................................................38
Figure 29 - Operating Program Window ..............................................................................................39
Figure 30 - Group Sequence Window...................................................................................................42
Figure 31 - Load Program Window ......................................................................................................44
Figure 32 - Save Program Window.......................................................................................................45
Figure 33 - Auto-Program Select Window ...........................................................................................52
Figure 34 - Power Off Rapping Window ..............................................................................................53
Figure 35 - POR Group Sequence Window ..........................................................................................55
Figure 36 - Typical Anti-coincidence Grouping ...................................................................................57
Figure 37 - Anti-Coincidence Window.................................................................................................57
Figure 38 - Troubleshooting Window...................................................................................................59
Figure 39 - R-Scan Window .................................................................................................................59
Figure 40 - Repeat Device Window ......................................................................................................61
Figure 41 - Smart System Profile Window ...........................................................................................64
Figure 42 - Calibration Window ...........................................................................................................65
Figure 43 - Smart-CPU Board Layout ..................................................................................................70
Figure 44 - Smart-Rap Board Layout ....................................................................................................72
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Introduction
Page 3
Chapter 1: Introduction
NWL’s Graphic Rapper Controller
NWL Transformers’ 3rd Generation rapper controller – The
Graphic Rapper Controller (GRC). Years of electrostatic
precipitator controls experience have resulted in the design of
this state-of-the-art rapper controller.
The GRC System consists of three major components (see
figure 1), the Smart-CPU (S-CPU), the Smart-Rap (S-Rap), and
the Hand-Held Programmer (HHP). The main function of the
S-CPU is to store and run complex operating programs. The SCPU offers many other features such as Power Off Rapping,
Trending, Anti-Coincidence Grouping making it the most
powerful rapper controller in the industry. The S-Rap module
operates in two fashions, “stand-alone” or part of the complex
system controlled by the S-CPU. When the S-CPU has control,
the S-Rap will energize devices and monitor the current levels
for alarm conditions. In stand-alone mode, the S-Rap uses
either on-board switch settings or internal memory settings to
energize and monitor the devices. Should the S-CPU have
trouble at any time, the S-Rap modules will automatically
switch to stand-alone and maintain rapper activity. The third
major component of the GRC System is the HHP. Through the
HHP, the user can create and modify operating programs,
monitor rapper activity and alarms, and troubleshoot system
faults. Using a graphical 16 line, 40 character Liquid Crystal
Display (LCD), the HHP provides the most information in the
industry.
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Introduction
Page 4
GRC Block Diagram
User Fieldbus
Connection
Optional
Fieldbus
Converter
Rapper 1…..16
External
Inputs
Smart
CPU
Smart
Rap 1
Rapper 17…32
Smart
Rap 2
Rapper 1009…1024
……..
Smart
Rap 64
I 2 C Link
RS 485 Link
Power
Supply
Hand Held
Programmer
Rapper Power
User
Input
= Communication Link
= High Power
= Low Power
Figure 1 - GRC Block Diagram
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Introduction
Page 5
Unique “Smart System” Features
R-Scan
The GRC’s R-Scan feature will check and report the operating
status of each rapper output within seconds. By applying a
small amount of power to each output, the GRC can determine
whether a device is within the preset normal operating ranges or
whether it requires attention by technicians. R-Scan reduces the
time for total system checkout to minutes rather than hours.
Today, with plant technicians assuming more responsibility than
ever, saving man-hours is not only a convenience, but also a
necessity.
Opacity Spike Detection
Creating operating programs without causing “opacity spikes”
due to re-entrainment has been the task of many plant engineers.
The GRC will monitor and detect opacity spikes caused by
specific rappers. This information eliminates the trial and error
method of creating the most efficient rapper program.
Support for Over 1000 Devices
The GRC will support up to 1024 devices on a single controller.
In the past, precipitators with a large number of rappers required
separate “stand-alone” controllers. Separate controllers meant
more hardware, more maintenance and more system attention.
With the technological advance in today’s microprocessors, the
limitations of the past are gone. The GRC brings total control
of a precipitator’s rapping responsibility to a single Hand-Held
Programmer. Increasing demands on the precipitator require
more complex rapping schemes. With the GRC, the plant
engineers tasks become more manageable.
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Introduction
Page 6
Auto-Lift Calibration
Temperature changes and rapper “wear and tear” cause changes
in a device’s performance. Constant attention had to be paid to
rappers in order to maintain optimum precipitator performance.
With the GRC, you simply select the desired lift in inches, and
the system will do the rest. Monitoring current levels and
making adjustments on the fly provides “lift regulation” in
changing conditions.
System Redundancy
When a rapper controller fails, ash begins to build up on plates
and may eventually cause a necessary precipitator shutdown.
With the GRC, you have the option for rapping redundancy.
The redundancy is accomplished with the S-Rap modules. Each
S-Rap will can be configured to automatically begin to fire each
output to maintain rapper activity in the event of an S-CPU
failure. Using this option provides the plant with a level of
redundancy virtually eliminating precipitator downtime due to
rapper controller failure.
Automatic Program Selection
Changes in operating loads of a precipitator require different
operating programs to maintain efficiency. The GRC will allow
automatic program changes based on boiler load ranges, time of
day, or remote input signals. Operators no longer have to worry
about changes to program settings when the levels of a
precipitator change.
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Introduction
Page 7
High Resolution, 16 Line x 40 Character Display
The GRC’s Hand-Held Programmer uses a graphical, 16 line,
40 character Liquid Crystal Display to provide the most
information in the industry. Graphical capabilities means
opacity and boiler load trending right at the programmer and a
simple “menu-driven” interface for ease of use. 16 lines of 40
characters means up to 640 characters on the display at one
time.
Opacity and Boiler Load Graphical Trending
Opacity and boiler load signals can be supplied to the GRC for
graphical trending and used for automatic system features. The
HHP provides a graphical trend of the information giving the
operator immediate feedback caused by changes to system
settings.
NWL’s Last ½ Cycle Variation
Several methods of obtaining precise lift are used in the
industry. Applying full ½ cycles of energy gives less control
over rapper lift. Phasing back ½ cycles to accomplish more lift
variations results in magnetism problems. NWL’s GRC uses a
combination of the two methods providing precise lift control
without causing magnetism. Applying full ½ cycles of power
and then phasing back power on only the last ½ cycle gives
repeatable lift control to the ½ inch.
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Introduction
Page 8
NWL’s Patented Ramped Intensity Pulsing – “Rip/Rap”
The energy applied to the lower area of precipitator plates is
reduced. In order to clean the bottom of the plate, higher rapper
lifts are required. This causes problems with re-entrainment.
When ash re-enters the gas flow, it’s either re-collected by the
next field or makes its way to the stack. NWL’s “Rip/Rap”
(Patent # 4928456), applies several “Rips” with increasing
energy levels. Each successive “Rip” will clear an area of the
plate eventually reaching the bottom. Before and after opacity
strip charts show significant reduction of spikes when Rip/Rap
is applied.
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Introduction
Page 9
Document Standards
Throughout this Guide we make use of some special typefaces
and print conventions to represent what you see on the display
and keys you push to operate the GRC Hand-Held Programmer.
Options you choose from a list or menu are written in
upper/lower case bold, such as Setup.
On-screen fields that allow you to make choices, set parameters
or displays information will be in upper/lower case bold italics:
Relay Logic.
Examples of information you enter into a field will be in
upper/lower case italics: On, Off, 15 Min.
The names of the keys you use to enter information on the
keypad will appear inside angle brackets: <Left Arrow>,
<Enter>.
Technical Support
NWL’s Environmental Technologies provides 24-hour support
for plant personnel. During normal business hours - 8:00AM to
5:00PM ET, NWL representatives can be reached at 1-800PICK NWL. After hours, the same number will access the
automated technical support system. Leave your name and
number and a NWL representative will return your call.
NWL has its own Website http://www.nwl.com where all GRC
software upgrades will be posted along with other product
enhancements.
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Introduction
Page 10
How to Use This Manual
The guide is divided into 6 chapters. Each chapter covers a
crucial aspect of the GRC operation.
Chapter 1: Introduction
Provides a summary of the GRC’s main features,
and general information related to this
document.
Chapter 2: Quick Start Guide
A simple checklist for initial GRC System
configuration.
Chapter 3: User Interface
An explanation of how to use the Hand-Held
Programmer for monitoring and configuration of
the GRC system.
Chapter 4: Troubleshooting
Detailed procedures for using the GRC’s built-in
troubleshooting features.
Chapter 5: Configuration Summary
A handy guide to the switch settings on the
Smart-CPU and Smart-Rap module.
The manual is designed to be a practical, user-oriented
description of each function and procedure. You’ll find it easy
to understand. Actual pictures of the on-screen displays are
included to make the text easier to follow.
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Introduction
Page 11
Chapter 2: Quick Start Guide
Use the checklist below to ensure proper configuration prior to
energizing the GRC System. For a more detailed description of
the Smart System board setup, see the Configuration Summary
chapter.
Smart-CPU Configuration
Board Address – Rotary Switch 1
Program the Serial Communication Address via HHP
Configure Power Feed Values via HHP
Create Operating Program via HHP
Create POR Program via HHP
Configure Anti-Coincidence Grouping via HHP
Program all S-CPU associated values (Load Scale, etc.) via
HHP
Optional – Configure the fieldbus converter parameters via
the HHP
Smart-Rap Configuration (each module)
Board Address – DIP Switch 8 (positions 3 through 8)
Each S-Rap Board Address is associated with assigned
rapper output range.
Calibration or Standard Lift Table for DC Impact
Devices – DIP Switch 8 (position 1)
Stand Alone On/Off – DIP Switch 1
Set Module Device type – DIP Switch 7
Select DIP or Internal Registers “Fire” Settings – DIP
Switch 2
For DIP Settings – set Device Fire Settings – DIP Switch 6
For Internal Register Settings – set Device Fire Settings via
HHP
Set Initial Wait, Cycle, and Wait Time – DIP Switches 3, 4,
&5
Select Gain setting – DIP Switch 10
Configure Overcurrent/Undercurrent settings via HHP
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Quick Start Guide
Page 12
Chapter 3: User Interface
Using the Hand-Held Programmer
Keypad
The GRC’s HHP keypad consists of just nine membrane keys
(see Figure 2). These keys demand positive operation. In other
words, you must exert some pressure on them before they
register. This helps eliminate accidental activation. However,
they are remarkably tough. Don’t be afraid to press hard. There
is a tactile response when they engage.
Figure 2 - HHP Keypad
The keys include:
Four <Arrow> keys (left, right, up, down) for moving around
within any window in the display area – called “scrolling” in
this manual.
<On/Off> which will activate/de-activate the operating
program.
<? Help> to access on-line help information for the GRC.
<Enter> used to move from the main menu at the top of the
screen to the data area. Also, used to register a choice or change
to a setting you have made.
<+Incr> and <-Decr> through which you change settings in the
entry windows.
Shortcut: Sometimes you may wish to return to the main menu
quickly, without changing any other settings in the entry
window. Similar to “Escape” on a computer keyboard, pressing
any two <Arrow> keys while the cursor is in the data entry area
of a window will return the cursor to the main menu.
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Page 13
User Interface
Menu Bars
The top two lines of the display are the main menu
(see Figure 3). Each option has one or more associated
windows and is accessible using the <Arrow> keys. Pressing
the <Enter> key on one of the selections will move the cursor
into the data entry area – provided you have the necessary
security clearance.
Figure 3 - HHP Menu Bars
Data Section
The middle of the display (lines 4 – 14) contains system settings
and option for entry into additional windows. The information
contained in the data section is determined by where the menu
bar cursor sits.
Figure 4 - HHP Data Section
Status Lines
The bottom line of the display is the status line and is used to
report system critical information to the user regardless of
which display is being viewed. Rapper activity, help messages,
and alarm information will all be displayed on the status line.
Figure 5 - HHP Status Lines
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Page 14
User Interface
On-Line Help
A major advantage of a multi-line display is the amount of
information that can be presented at one time. The HHP
contains on-line help information available for immediate
access. Simply press the <?Help> key and information relevant
to the current window will be displayed. Descriptions of system
settings and their ranges are available.
Figure 6 - On-Line Help Window
Signing On
The GRC System uses password-controlled security to prevent
unauthorized personnel from making changes to system
settings. Access to several windows requires the user to log on
to the system. Enter the 2 character alphanumeric password at
the Sign On using the <+Incr> and <-Decr> keys and press
<Enter>. If a valid password is entered, the cursor will return to
the Monitor window and Sign Off will replace Sign On on the
menu bar. When you’re finished making changes, simply press
<Enter> on the Sign Off option. If you forget, the HHP will
automatically log off within a period of inactivity.
Figure 7 - Sign On Window
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Page 15
User Interface
Monitoring
Rapper Activity
The Monitor window provides operators with a 9-second
window of the GRC System’s rapper activity. Up to 6 rappers
can be energized in 1 second.
Figure 8 - Monitor Window
PROGRAM STATUS
Pressing <Enter> on this field will open the Program Status
window.
ACG FIFO
Pressing <Enter> on this field will open the Anti-coincidence
FIFO (First In First Out) window.
TREND
Pressing <Enter> on this field will open the Opacity and Boiler
Load Trend window.
-4 … 0 … 4
If the operating program is running, the Monitor window will
show the current rapper activity. For example, the line of
activity at –4 represents rappers that are scheduled to fire in
approximately 4 seconds. Line 0 will show rappers that have
just been energized.
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Page 16
User Interface
S-CPU
This field contains the address of the currently selected S-CPU
module (1-16). To select a different S-CPU, press the <+Incr>
or <-Decr> key and press <Enter>. The HHP will start to
monitor the rapper activity and alarm information for the new SCPU.
Prog
Each S-CPU can hold 5 operating programs. This field shows
which of the 5 programs is selected. To change the active
program, press the <+Incr> or <-Decr> key and press <Enter>.
If the program selected is valid, the S-CPU will start to run the
new program, otherwise an error message will be displayed.
Operating Programs
While creating and modifying operating programs, an operator
can use the Program Status window to “watch” the program in
action. This window will display the times and next rapper
scheduled to fire for each group. Press the <+Incr> or <-Decr>
key to change which groups are monitored.
Figure 9 - Program Status Window
Grp#
Shows the current rapper group (1-64).
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Page 17
User Interface
InitWait
Display the amount of initial wait time remaining for a rapper
group. If this value is at 00:00:00, the rapper group is in either
cycle or wait time mode.
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Page 18
User Interface
Cycle
Displays the amount of cycle time remaining for a rapper group.
When the cycle time counts down to 00:00:00, the NextRap will
be energized.
Wait
After completing a rapper sequence, a group will enter a wait
period (if programmed to do so). Once the wait time counts
down to zero, the group will re-enter the cycle mode and start to
energize rappers again.
NextRap
This field shows the next rapper schedule to fire for group.
Anti-Coincidence Buffers
During normal rapper program operation, an Anti-coincidence
scheme (see ACG in Configuration chapter) can be setup to
prevent “gas-flow” rapping and eventual re-entrainment. The
ACG FIFO will display rappers that are currently held due to
ACG conflicts.
Figure 10 - Anti-Coincidence Buffer Window
ACG#
Shows the Anti-coincidence group number (1-64).
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Page 19
User Interface
Timer
Indicates the amount of time remaining for the ACG. When this
time counts down to 0, the next device in the FIFO will be
scheduled to fire and has priority over the normal rapper
activity.
FIFO
FIFO, or First In First Out, shows the list of devices that have
been held due to a ACG conflict. As the name implies, the first
rapper entered into the list is the first to be removed.
Alarms
The S-CPU module will continuously monitor for S-Rap
alarms. The bottom right corner of the display will indicate
whether any alarms exist.
Figure 11 - Status Line Alarm Notification
User will be notified if any of the following alarms
occur:
1) Operating Program is OFF.
2) SRAP alarm(s):
a) S-RAP does not communicate with the S-CPU
b) Overcurrent, Undercurrent, or Half-wave occured
User will be notified of the Alarm(s) by the word ALARMS
that will appear on the Status line. To determine what kind of
alarm(s) occurred User will select ALARMS from the Status
Line of the HHP and press <Enter> key.
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Page 20
User Interface
The screen will change to S-RAP Alarm Summary screen that
is shown below.
Figure 12 – S-RAP Alarm Summary screen
2, 3, 4, 5, ..
The numbers are the Board Addresses of S-RAP(s) being
alarmed. To determine what kind of S-RAP alarm (s) occurred
User will select the S-RAP and press <Enter> key on the HHP.
The screen will change to SRAP Alarms screen for the
particular S-RAP. The screen is shown below.
Figure 13 - S-RAP Alarms screen
S-Rap
Shows the address of the currently selected S-Rap module.
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Page 21
User Interface
#/OK
The operating status of each output on the S-Rap module will be
stored. The operator can manually disable an output by using
the <+Incr> or <-Decr> keys and pressing <Enter>. The 2
character text next to the output number represents the status
(see table below).
Alarm
OK
DS
OC
UC
HW
SO
SU
SW
Description
Functioning properly
Manual disabled
Failed on overcurrent check
Failed on undercurrent check
Failed on half-waving check
Suspected of failing on overcurrent
Suspected of failing on undercurrent
Suspected of failing on half-waving
CLEAR ALL ALARMS
Pressing <Enter> on this field will clear the alarms on all each
S-Rap outputs.
Comm OK/No Comm
Shows whether a particular S-Rap communicates (Comm OK)
or does not communicate (No Comm) with the HHP.
Trending
The HHP uses it’s graphical capability to display a 1-minute
trend of the opacity and boiler load signals.
Figure 14 - Opacity and Boiler Load Trend Window
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Page 22
User Interface
S-CPU
Shows the address of the S-CPU currently selected.
Opacity
Shows the value of the opacity 4-20mA input on the S-CPU
module. The input scale of the opacity is always 0 to 100%.
However, the HHP will automatically re-scale the display to
provide a better trend.
Boiler Load
Shows the value of the boiler load 4-20mA input on the S-CPU
module. The scale of the boiler load is setup in the S-CPU
window (see S-CPU in Configuration chapter).
Figure 15 - Opacity Spike Detect Window
Rappers that are suspected of causing opacity spikes will be
displayed in this window. When an opacity spike is detected,
all rappers that fire within the Flow Delay (see Smart-CPU
window) will be flagged. Rappers that are flagged in three
consecutive occurrences will be logged to this list.
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Page 23
User Interface
Configuration
Smart-CPU
The S-CPU module requires setup of several values for proper
system operation.
Figure 16 - Smart-CPU Window
S-CPU
This field shows the address of the currently selected S-CPU
module.
Version
Shows the version of firmware loaded into the SCPU card.
Password
To prevent unauthorized or accidental parameter entry, the HHP
requires an operator to sign on with a proper password. The
password is a 2 digit alphanumeric value. Programmable from
00 – ZZ. If the user is not signed on, this field will be displayed
as **.
Relay Logic
When the number of rapper alarms (Num Alarms) is reached,
the S-CPU will activate the alarm relay. This relay can be used
to notify operators in a control room, sound an alarm horn, or
simply light an indicator. The logic of the relay is
programmable as N.O. (normally open – closes on alarm), or
N.C. (normally closed – opens on alarm).
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Prog Off
If you would like the GRC to generate an alarm if the rapping
program is turned off, set this parameter to Alarmed. If you
want to be able to turn the rapping program off without getting
an alarm set this parameter to No Alarm.
Num Alarms
Being notified of every alarm may eventually become a
nuisance. By setting the number of alarms value to something
other than 1, the S-CPU will delay activation of the alarm relay
until that number of alarms occurs. Programmable from 0 – 99.
Prg Restart
When the operating program is turned on, the S-CPU will either
re-start the program or continue from where it previously left
off. Re-starting the operating program causes all timers to be
initialized at 0 and the sequence pointer returns to the start of
the rapping sequence. Programmable as Continue or Re-start.
Load Scale
If the boiler load 4-20mA signal is connected to the S-CPU, the
scale value represents what value should be displayed at 20mA
or full scale. Programmable from 0 – 9999.
Flow Delay
The flow delay is defined as the amount of time it takes for gas
to completely travel through the precipitator. This value is used
for determining which devices are suspected of causing opacity
spikes. Programmable from 0 – 99 seconds.
Opacity Spike
The GRC system has a unique feature that identifies which
rappers are suspected of causing opacity spikes. This value
defines what percentage of an increased in sudden opacity is
required to enable a opacity spike scan. Programmable from 0 –
99%.
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CLR OPAC SPK LIST
Pressing <Enter> on this field will send a command to the SCPU to clear its current list of rappers suspected of causing
opacity spikes. This is useful for resetting the list after a new or
modified program is being tested. The Status line will briefly
flash a message confirming the command has been sent.
Time
The S-CPU module contains a built-in timekeeper. Use the
<+Incr> or <+Decr> key to change the hours, and press
<Enter>. The cursor will move to the minute’s field. Continue
changing the minutes, and seconds and finalize you selection by
pressing <Enter>. The new time value will be sent to the SCPU. The format of the Time value is 00:00:00 to 23:59:59.
The time value can be used by the S-CPU to automatically
change operating programs.
Date
Similar to the Time field above, the S-CPU will store the date.
Currently, the date is informational only.
Rem. Enable:
Note: Please, refer to the GRC System schematics for reference
designators.
This is a software switch that will allow the User to operate the
GRC in Local or Remote modes. The switch has 3 settings:
Disabled, Discrete, and Network. To change from one setting
to another use +/- key on the HHP keypad.
a) Disabled
This is a default setting. It will appear on the HHP screen when
the new software is installed on the S-CPU board.
Most of the Users will operate in this mode. They will be able to
send write commands to the GRC locally (from HHP) and
remotely (PCAMS/NT and DCSi).
b) Discrete
In this mode the system software will monitor and respond to
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Rem_Prg_On input (1TB – 22 on the GRC System schematics)
as long as the system configured to Remote mode (120VAC is
applied to Loc/Rem Enable input located on 1TB – 21 on GRC
System Schematics).
If system is configured to Remote mode all write commands
from HHP will be rejected. Write commands can be sent via
PCAMS/NT or DCSi (except Program ON/OFF command).
To turn the Program ON remotely 120VAC must be applied to
Rem_Prg_On input (1TB – 21 on GRC System schematics).
To turn the Program OFF remotely 120VAC must be
disconnected from Rem_Prg_On input.
If 120VAC is not applied to Loc/Rem Enable input then
the system will be in Local mode which means that write
commands from HHP only will be accepted.
c) Network
In this mode the system software will monitor and respond to
commands originating from PCAMS/NT or DCSi only as long
the system configured to Remote mode (120VAC is applied to
Loc/Rem Enable input located on 1TB – 21 on GRC System
schematics). If system is in Remote mode all write commands
from HHP will be rejected, all write commands from
PCAMS/NT and DCSi will be accepted.
If 120VAC is not applied to Loc/Rem Enable input (1TB – 21
on GRC System schematics) then the system will be in Local
mode and accept write commands from HHP only.
Fldbus Ctrl
This parameter is used to define which port is to be able to write
commands to the GRC. If set to NWL Net, the Net Port is the
only port able to write commands. If set to Fielsbus, only the
optional fieldbus module is able to write commands. If set to
All, both the Net Port and the fieldbus module can write
commands.
NetPrt Baud
This parameter sets the baud rate for the Network port. The
possible settings are, 9600, 19200, 38400, 57600, and 115200.
In order for the GRC to communicate with the NWL PCAMS or
GRC-DCSi the baud rate should be set for 19200.
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NetPrt Mode
The protocol for network port is selectable between NWL and
Modbus. In NWL mode, our proprietary protocol is used to
communicate with other NWL products. In Modbus mode, the
Modbus RTU protocol is used for communications with a PLC
or other host computer. The datamap for this mode is located
an the appendix of this manual.
Local/Remote Control Table
“Remote Enable”
Setting
Disabled
“Local/Remote”
Discrete Input
State
Local Port (NWL
protocol only)
Remote Port (NWL
protocol or
Modbus-RTU)
Anybus Port
“Program On/Off”
Discrete Input
“Program Select”
Discrete Inputs
Local or Remote
Write access
Write access if
“Remote Master”
is set to “Net Port”
or “All”
Write access if
“Remote Master”
is set to “Fieldbus”
or “All”
Disabled
Enabled
Local
Write access
Read-only
Read-only
Disabled
Disabled
Remote
Read-only
Read-only
Read-only
Enabled
Enabled
Local
Write access
Read-only
Read-only
Disabled
Disabled
Remote
Read-only
Write access if
“Remote Master”
is set to “Net Port”
or “All”
Write access if
“Remote Master”
is set to “Fieldbus”
or “All”
Disabled
Disabled
Discrete
Network
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SUB-MENUS
There are four additional sub-menus for the SCPU board. They
are shown below.
Figure 17 – Sub-Menu Window
AUTO PROGRAM SELECT
Pressing <Enter> on this field will open the window for
configuring the automatic program selection feature of the GRC
System. See the Auto Select section under the Configuration
portion of this manual for more details.
POWER FEED CONFIGURATION
defining which slots are connected to each power feed. See the
Power Feed section under the Configuration portion of this
manual for more detail.
Optional Fieldbus Converter
If an optional fieldbus converter is installed on the SCPU board,
that type of fieldbus will be designated in the FIELDBUS =
field. Pressing <Enter> on this field will open the window for
configuring the protocol parameters for the specific fieldbus .
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Figure 18 – Ethernet I/P Configuration Window
Enter the appropriate data for each parameter. Press <Enter>
after each entry. Consult with your network administrator for
the proper parameter values to be entered.
The Fieldbus Configuration Screens will vary slightly
depending upon the specific Fieldbus being used. Ethernet I/P
and Modbus TCP use the display shown above. Other examples
of Fieldbus displays are shown below.
Figure 19 – Profinet Configuration Window
Figure 20 – DeviceNet Configuration Window
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Figure 21 – Modbus RTU Configuration Window
Figure 22 – Profibus Configuration Window
When complete scroll down to the APPLY CHANGES and
press <Enter>. The cursor will move to the RETURN TO
SETUP field. Press <Enter> to return.
Installing the Optional Field Bus Converter
If the rapper contrroller was ordered with the optional fieldbus
converter, it will be install at the factory. However, if you need
to replace the SCPU board, the converter must be moved from
the old board to the new board. To remove the old converter:
1. Remove the field wiring connector that plugs into the
converter.
2. Remove the SCPU board from the card cage and place on a
flat surface.
3. Turn the two screws on the front plate of the converter
counter-clockwise to release the converter from the DSP
board.
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4. Grab the sides of the converter and gently pull it from the
multi-pin jack.
Once removed follow the steps below to install it on the new
board.
1. Make sure that the mounting feet on the module are fully
retracted by turning the two screws on the front plate
counterclockwise.
2. Carefully line up the module with the mounting rails of the
jack. Slowly and carefully start to slide the module into the
jack. As the module approaches the pins in the back of
the jack, stop and visually verify that all of the pins in
the jack are properly aligned and entering the sockets in
the module. If the pins are not properly aligned damage
will occur to the jack on the DSP board. If the pins are all
aligned, continue to slowly push the module into the jack
until it is fully seated.
3. Turn the two screws on the front plate of the module
clockwise to secure the module to the DSP board.
4. Replace the SCPU card in the card cage.
5. The users wiring will then connect directly to the connector
on the field bus module.
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SD-Card
The DSP processor board also has provisions for a 2 or 4 GB
SD memory card. The card is located under DSP board near the
optional fieldbus module socket.
Figure 23 – SD Card Location
The SD card holds the following files:
• User Rapping Programs
• User ACG Data
• GRC Configuration files.
Pressing <Enter> on SD-CARD FUNCTIONS on the Sub Menus
screen will open the following window.
Figure 24 – SD-Card Function Window
Scroll down to the desired command and press <Enter> for the
action to initiate.
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Smart-Rap
Each S-Rap module stores information specific to its operation.
For example, the operating status of each of the 16 rapper
outputs is stored. Also, the internal register settings for use in
“stand-alone” operation or configured through this window in
Rapper Setup.
Figure 25 - Smart-Rap Window
S-Rap
RAPPER SETUP
Pressing <Enter> on this field will open the Rapper Setup
window for configuration of the S-Rap’s internal register
settings.
ALARMS
Pressing <Enter> on this field will open the Alarms window for
viewing the alarm status of the 16 rappers on the current S-Rap
module.
Relay Logic
The logic of the S-Rap module alarm relay is programmable as
N.O. (normally open – closes on alarm), or N.C. (normally
closed – opens on alarm).
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Rapper Setup
When a S-Rap module is configured to operate in “stand-alone”
mode, the information used for firing the rappers is setup in this
window. In addition to stand-alone operation, the GRC System
S-Rap module will automatically initiate firing rappers with
these settings in the occurrence of a S-CPU failure.
Figure 26 - Rapper Setup Window
S-Rap
Rap#
Shows the rapper output number (1-16) on the S-Rap module.
Lift
Sets the lift in inches for DC Impact type rappers. This value is
used in stand-alone and auto-redundant modes only.
Programmable from 0 – 16 inches.
Lift Reg: On/Off
Turns the Lift Regulation ON and OFF. If the Lift Regulation is
ON then the number of half-cycles will be adjusted to achieve
the desirable Lift value; if the Lift Regulation is OFF then the
number of half-cycles will not be adjusted.
[AC/DC Mot]
Current Device Type that S-RAP board is controlling
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Frq
Sets the frequency in cycles per minute for Multi-Impact type
devices. Programmable in 13 preset steps from 200 to 600
CPM. Valid values are 200, 212, 225, 240, 257, 278, 300, 330,
360, 390, 450, 510, and 600. Press the <+Incr> or <-Decr> key
to scroll through the available settings and press <Enter> to
accept the change.
Int
Sets the intensity percentage for Vibrator and Multi-Impact type
devices. Programmable from 0 – 100%. Changes to the
intensity less than 100% will result in ½ cycles of power applied
at less than full conduction.
Duration
Sets the duration in seconds of Vibrator, Multi-Impact, and
Motor type devices. Programmable from 00:00:00 to 23:59:59.
UC/OC
Each rapper output can be assigned current low and high alarm
levels. When the S-Rap module detects 2 consecutive ½ cycles
of current lower than the UC setting, it will flag the rapper
output. Two consecutive failures will result in the output to be
alarmed and removed from normal firing activity. The same
will occur when the S-Rap detects a single ½ cycle of current
higher than the OC setting. Programmable from 0 to 40
amperes.
Hand-Held Programmer
The HHP contains local configuration settings specific to its
operation. These settings are stored in the HHP and retained in
the event of a power outage.
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Figure 27 - Setup Window
HHP Address
Serial communication address for Hand-Held Programmer.
Programmable from 3 - 9.
Keypad Beep
On/Off switch for audible beep when keys are pressed.
Code Timeout
Amount of time before HHP will sign off when there is no key
activity. Programmable from 1 - 30 minutes.
Light Timeout
Amount of time before LCD backlight turns off when there is
no key activity. Programmable from 1 - 30 minutes.
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Power Feeds
Figure 28 - Power Feed Window
X1 – X6
The GRC System allows up to 6 separate power feeds. Each
power feed is assigned to one or more S-Rap cards. Proper
configuration of the power feeds is critical for rapper operation.
Take a simple example of a GRC System with three S-Rap
modules. S-Rap1 and S-Rap2 modules are responsible for
energizing 16 DC-Impact style devices each. S-Rap3 module is
responsible for energizing 16 AC Vibrator devices. The power
feed assignments for X1 should be S-Rap 1 to 2 and X2 should
be assigned S-Rap 3 to 3. The GRC System’s S-CPU utilizes
this information to enable simultaneous rapper operation and to
prevent system damage. For safety reasons, if the power feeds
are not assigned, the S-CPU will not energize any rappers.
Operating Programs
The most important aspect of a rapper controller is the creation
of optimum rapping programs. Rapper programs consist of
timing values, lift information, etc. and are all important to
achieving optimum performance. Either through experience or
trial and error, operators can fine tune programs to produce the
most effective results in the precipitator. The GRC System
supports what the industry considers a “time-based” rapper
controller. This type of controller is more flexible than older
style “sequence-based” rapper controllers. Independent groups
of rappers can be assigned different timing values. This is
important for rapping inlet fields more often than center fields,
and center fields more often than outlet fields. The GRC offers
the most complex program capabilities in the industry. Up to 64
groups, 48 rappers per group, individual settings per rapper, and
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no limitation on assigning rappers to more than one group
provide the user with the flexibility to create just about any
program they desire. Of course, with the amount of information
to be entered, rapper controllers of the past - using 1-4 line
displays – were difficult to use. The HHP’s 16 lines of
information make program entry simple and easy to follow.
The user can “upload” a program into the memory of the HHP
and make modifications while rapper firing continues in the
background. When the changes are complete, the program can
be saved or “downloaded” to the S-CPU and stored in FLASH
memory.
Figure 29 - Operating Program Window
S-CPU
Shows the address of the currently selected S-CPU module.
LOAD
Pressing <Enter> on this field will open the window for loading
a program from the S-CPU into the HHP’s memory.
SAVE
Pressing <Enter> on this field will open the window for saving
a new program to the S-CPU’s memory.
CLEAR
This field will clear the program information in the HHP only.
(All parameters reset to “0”) Pressing <Enter> will open a
dialog box: “Confirm program clear?” “Press enter again to
confirm”. Pressing any <Arrow> key at this point will prevent
the “clear” function and take you back in the program screen.
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Grp#
Shows the current group number (1-64). Pressing the <+Incr>
or <-Decr> key on this field will scroll the display to a new set
of 8 groups.
InitWait
The initial wait time of a group is defined as the “one-time”
delay before initiating rapper activity. The initial wait time is
useful for offsetting groups of rappers with identical timing.
For example, groups 1 and 2 both have 10 rappers and a cycle
time of 30 seconds (see Cycle time below). With an initial
delay of 0, both groups will schedule rappers to fire at the same
time. By assigning a 30-second initial wait time to group 2,
group 1 will be completed firing before group 2 starts.
Programmable from 00:00:00 to 23:59:59. See program
example section below for a better understanding of the timing
interaction.
Cycle
The cycle time of a group is defined as the amount of time it
takes to completely “cycle” through all the assigned rappers.
Rappers will be evenly space throughout a group’s cycle time.
For example, a group with 10 rappers and a cycle time of 30
seconds will attempt to fire a rapper every 3 seconds (30 / 10 =
3). Groups that have 0 cycle time will be disabled regardless of
whether rappers are assigned. Programmable from 00:00:00 to
23:59:59. See program example section below for a better
understanding of the timing interaction.
Wait
The wait time of a group is defined as the amount of time to
delay after the completion of a cycle period before restarting the
cycle mode. For example, a group is assigned a wait time of 30
seconds. When the group completes the rapper sequence (fires
all rappers), it will “sleep” for 30 seconds and not attempt to fire
any rappers. After the 30 second delay, the group will re-enter
the cycle mode and attempt to fire rappers. Programmable from
00:00:00 to 23:59:59. See program example section below for
a better understanding of the timing interaction.
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MODE
With the release of Scpu firmware version 3.00, HHP firmware
version 3.00 and Srap firmware version 2.00, the GRC system
allows for different “modes” of how the rappers will function.
There are five modes to choose from.
1).
Norm
This mode will raise the individual rapper once, at the assigned
lift entered in the SEQ field, before moving onto the next rapper
in that group sequence.
2).
Rip
This mode is used to turn the GRC feature “Rip/Rap” On.
When Rip is selected, the DC Impact devices will be fired using
the Rip/Rap algorithm. Four “Rips” of power with increasing
energy are applied to the rappers with the fourth “Rip” equal to
the assigned Lift entered in the SEQ field.
3).
2X
This mode will raise the individual rapper two times in
succession, at the assigned lift entered in the SEQ field, before
moving onto the next rapper in that group sequence.
4).
3X
This mode will raise the individual rapper three times in
5).
4X
This mode will raise the individual rapper four times in
NOTE:
For proper operation, when selecting the Rip, 2X, 3X, or 4X modes, ensure the groups
cycle time is set to allow a minimum of 2 seconds for each DC Impact device.
For example, lets say group #1 consists of 90 rappers and Rip is selected, the group
cycle time, at a minimum, would need to be set to 180 seconds or 3 minutes.
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SEQ
configuring the rapper sequence information for the associated
group.
Rapper Sequence
Figure 30 - Group Sequence Window
Group
Shows the current group number (1-64) of the sequence
information being displayed.
Assign .. to ..
GO
These fields provide a shortcut for assigning rapper output
numbers to a sequence(s). Set the starting and ending rapper
output number and press <Enter> on GO. The HHP will
automatically assign rappers to the group’s sequence.
Seq#
Shows the current sequence number (1-48). Do not confuse
with the rapper output number. Output number (1-1024) is
linked to a particular S-Rap board address (1-64). Please, refer
to Ch6. Configuration Summary (S-Rap section) for more
information. Sequence number is a way of counting the number
of rappers in a group. For example, if the group has 5 rappers
then Seq# will range from 1 to 5. Pressing <+Incr> or <-Decr>
on these fields will scroll the display to the next/previous set of
sequence numbers.
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Rap#
This field represents the rapper output number to fire when this
sequence member is scheduled. The rapper numbers can be
auto-assigned using the Assign option or by using the <+Incr>
and <-Decr> keys. When a “gap” in the sequence is desired, a 0
can be entered. To complete the sequence, change the field
below the last member to >end. Programmable from 0 – 1024
or >END.
Lift
If the rapper assigned for this sequence member is a DC Impact
type device, enter the desired lift in inches. Otherwise, this field
is ignored. Programmable from 0 to 16 inches in .5 inch steps.
Freq
If the rapper assigned for this sequence member is a MultiImpact type device, enter the desired frequency in cycle per
minute. Programmable in 13 preset steps from 200 to 600
accept the change.
Int
If the rapper assigned for this sequence member is a Vibrator or
Multi-Impact type device, enter the desired intensity value in
percentage. Programmable from 0 – 100%. Changes to the
This field must be set to 0 for AC/DC Motor type devices to
prevent inaccurate results in Program Timing check..
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Duration
If the rapper assigned for this sequence member is a Vibrator,
Multi-Impact, or Motor type device, enter the desired duration
value in seconds. Programmable from 00:00:00 to 23:59:59.
For DC Impact type devices, verify this value is 00:00:00 to
prevent inaccurate results to the program timing check.
Program Timing Check
The HHP will perform a timing check on the operating program
and verify the system has the capability to fire all devices before
allowing it to be saved to the S-CPU. This prevents “lost”
rappers due to timing constraints.
Program Timing check will not be invoked for AC/DC Motor
type devices.
Program Load
The S-CPU will store up to 5 operating programs. The HHP
will store one operating program. Use the HHP Load option to
retrieve a program to modify.
Figure 31 - Load Program Window
Program
Use the <+Incr> or <-Decr> keys to select the operating
program number and press <Enter>. The HHP will begin to
upload the program from the S-CPU. Select the program “F” to
load the program from the HHP’s flash memory.
Status
The Status field will indicate which information is currently
being retrieved and a percentage completion. If an error occurs
during “upload”, it will be reported in this field.
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Program Save
When all desired changes are made to the operating program, it
must be saved to the S-CPU before it can be used. Rapper
activity will be temporarily suspended during program
download. When download is complete, the program
automatically continues from where it left off. If the “active”
operating program is overwritten, the S-CPU will re-start the
new program.
Figure 32 - Save Program Window
Program
Use the <+Incr> or <-Decr> keys to select the operating
program number and press <Enter>. The HHP will begin to
download the program to the S-CPU. When the program
download process is complete, the S-CPU will enter a “Burn
FLASH” mode that will take approximately 2 minutes to
complete. Select program “F” to save the program to the HHP’s
flash memory.
Status
The Status field will indicate which information is currently
being saved and a percentage completion. If an error occurs
during “download”, it will be reported in this field.
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Operating Program Example
The following example will illustrate typical program for a
better understanding of the interaction of groups and their
associated times. This first example does not take into account
the possible anti-coincidence delays or Power Off Rapping
devices that may affect rapper scheduling. All rappers in this
program example are DC Impact type devices.
Given the following program:
Group
1
Init. Wait
00:00:05
Cycle
Wait
00:00:10 00:00:00
Mode
Norm
2
00:00:05
00:00:10 00:00:10
Norm
3
00:00:05
00:00:10 00:00:00
Norm
Seq.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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When the program is turned on (time 0), the following table
illustrates when rappers will be scheduled to fire:
Time
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Group 1
Group 2
Group 3
1
6
11
2
7
12
3
8
13
4
9
14
5
10
15
1
11
2
12
3
13
4
14
5
6
15
1
7
11
2
8
12
3
9
13
4
10
14
Since groups 1 and 3 have identical cycle and wait times and
same number and type of rappers all rappers in those groups
will fire with the offset of 250 milliseconds (they need to be
offset to prevent transformer overload).
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ACG Affect on Program
Configuring a GRC with Anti-Coincidence (ACG) will have an
affect on the normal rapper activity. With the same program
above, we’ll add the following ACG’s:
ACG Time is 5 seconds
ACG 1 contains device # 1 and # 11
Note: rappers that are in the ACG group are enclosed in ().
Time
Group 1
Group 2
Group 3
0
1
2
3
4
5
(1)
6
6
7
2
7
12
8
9
3
8
13
10
(11)
11
4
9
14
12
13
5
10
15
14
15
(1)
16
17
2
12
18
As you can see, device 11 caused an ACG
19
3
13
conflict with device 1 and was therefore
20
(11)
delayed for 5 seconds before firing.
21
4
14
22
23
5
6
15
24
25
(1)
7
26
27
2
8
12
28
29
3
9
13
30
(11)
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POR Affect on Program
Power Off Rapping programs are similar to normal operating
programs. Each POR group is assigned a device sequence with
associated firing parameters, and group timing (i.e. cycle time,
etc.). Each POR group is also assigned an associated T/R
number that is powered down prior to firing the devices in a
POR group’s sequence. Once rapping is complete, the T/R is
returned to its previous power levels. This type of rapping is
useful for effective fly-ash removal in high-resistivity
conditions.
Given the first example above (no ACG), let’s add a simple, 1
group POR program shown below:
POR
Group
1
Init. Wait
00:00:00
Cycle
Wait
00:00:05 23:59:55
T/R #
Seq.
1
1
2
3
4
5
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User Interface
Time
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
POR 1
1
2
3
4
5
Group 1
Group 2
Group 3
1
6
11
2
7
12
3
8
13
4
9
14
5
10
15
1
11
2
12
3
13
4
14
5
6
15
1
7
11
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Page 50
User Interface
Selecting an Operating Program
An Operating Program that User wishes to run can be selected
Manually or Automatically. Manual selection can be
performed via HHP or Program Select inputs on the S-CPU;
automatic selection can be done using an Auto Program select
feature of the GRC system.
Prior to selecting an Operating Program Rem Enable software
switch located on the S-CPU window of the HHP must be set to
Disabled.
An operating program can be selected by HHP or by Program
Select inputs of the S-CPU.
Selecting an operating program via HHP
To select an active operating Program via HHP the following
steps have to be taken by the User:
1)
2)
1)
4)
5)
6)
7)
Select Monitor on the Main Menu of the HHP and press
<Enter> key.
Scroll using right arrow key to the S-CPU:
Enter the S-CPU address that the Program will run on.
Scroll to Prog: and enter the Program # that needs to
run.
Press <Enter> key.
Turn the Program ON.
Check the Monitor screen. The active program number
will be shown under Prog:
Selecting an Operating Program via Program Select Inputs of
the S-CPU
To select an active operating Program via the Program Select
inputs the following steps have to be taken by the User:
1) Turn the system OFF
1) To run Program 1: apply 120VAC between 1TB – 4 and
1TB – 9 on the GRC Cabinet Backpanel.
To run Program 2: apply 120VAC between 1TB – 5 and
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Page 51
User Interface
2) Select Monitor from the Main Menu on the HHP and
press <Enter>
3) Prog: <selected program> should be dispalyed. The User
will see Prog: <selected program> ON indication on the
HHP.
Auto-Program Select
Automatic changes to the active operating program can be
triggered either by boiler load or time of day. This eliminates
the need for operators to make constant program changes
throughout the day or when load changes occur in the
precipitator. Experience shows that different boiler loads
require different operating programs to maintain an optimum
level of performance.
Figure 33 - Auto-Program Select Window
S-CPU
AP Status: ON/OFF
AP Status: ON enables the Auto – Program feature of the
system; AP Status: OFF disables the Auto – Program feature.
Default Program
When the S-CPU performs the auto-program select algorithm
and no matches are found, the default program will be used.
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User Interface
Boiler Load .. to ..
Program
Set the minimum and maximum boiler load ranges and the
associated operating program. The S-CPU will then
automatically make the changes for you as the boiler load
changes. In order to enable this feature, the 4-20mA boiler load
signal must be connected to the S-CPU module.
Time .. to ..
Program
Automatically switch to a “faster” program at midnight or
switch programs at each shift change. Simply set the time
ranges and associated program and the changes will
automatically occur. Verify the S-CPU time is set properly.
Power Off Rapping
Separate from the normal operating programs, rappers can be
scheduled to fire while power is removed or reduced from T/R
sets. This type of rapping provides a more effective cleaning
especially in situations with “sticky” fly ash. An output can be
assigned to each Power Off Rapping (POR) group to signal
third party T/R’s to reduce or remove power while POR occurs.
NWL’s Precipitator Management and Control System for
Windows NT (PCAMS/NT) will monitor the GRC for POR
activity and automatically reduce power to the associated NWL
ESP Power Optimizer T/R controller. The GRC System
supports up to 32 POR groups with 48 sequence members per
group. Several POR program parameters are identical to normal
operating program’s parameters but will still be covered in this
section for simplicity.
Figure 34 - Power Off Rapping Window
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Page 53
User Interface
S-CPU
LOAD
Pressing <Enter> on this field will open the window to upload
the POR program.
SAVE
Pressing <Enter> on this field will open the window to save or
download the POR program.
Grp#
Shows the current POR group number (1-32). Pressing <+Incr>
or <-Decr> on these fields will scroll the display to the
next/previous set of POR group numbers.
InitWait
The initial wait time of a POR group is defined as the “onetime” delay before initiating rapper activity. Programmable
from 00:00:00 to 23:59:59.
Cycle
The cycle time of a POR group is defined as the amount of time
it takes to completely “cycle” through all the assigned rappers.
Programmable from 00:00:00 to 23:59:59.
Wait
The wait time of a POR group is defined as the amount of time
to delay after the completion of a cycle period before restarting
the cycle mode. Programmable from 00:00:00 to 23:59:59.
Out#
The output number is used to notify third-party T/R controllers
prior to initiating rapper activity for a POR group.
Programmable from 0 to 1024. Note, the output number must
be an output located on a Smart-Rap card configured for POR
output.
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Page 54
User Interface
SEQ
configuring the rapper sequence information for the associated
POR group.
Figure 35 - POR Group Sequence Window
POR Group
Shows the current POR group number (1-32) of the sequence
information being displayed.
Assign .. to ..
GO
These fields provide a shortcut for assigning rappers to a
sequence. Set the starting and ending rapper number and press
<Enter> on GO. The HHP will automatically assign rappers to
the POR group’s sequence.
Seq#
Shows the current sequence number (1-48). Pressing <+Incr>
next/previous set of sequence numbers.
Rap#
This field represents the rapper output number to fire when this
sequence member is scheduled. The rapper numbers can be
auto-assigned using the Assign option or by using the <+Incr>
and <-Decr> keys. When a “gap” in the sequence is desired, a 0
can be entered. To complete the sequence, change the field
below the last member to >end. Programmable from 0 to 1024.
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Page 55
User Interface
Lift
If the rapper assigned for this sequence member is a DC Impact
type device, enter the desired lift in inches. Otherwise, this field
is ignored. Programmable from 0 to 16 inches in .5 inch steps.
Freq
If the rapper assigned for this sequence member is a MultiImpact type device, enter the desired frequency in cycle per
minute. Programmable from in 13 preset steps from 200 to 600
accept the change.
Int
If the rapper assigned for this sequence member is a Vibrator or
Multi-Impact type device, enter the desired intensity value in
percentage. Programmable from 0 to 100%. Changes to the
Duration
If the rapper assigned for this sequence member is a Vibrator,
Multi-Impact, or Motor type device, enter the desired duration
value in seconds. Programmable from 00:00:00 to 23:59:59.
For DC Impact type devices, verify this value is 00:00:00 to
prevent inaccurate results to the program timing check.
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Page 56
User Interface
Anti-Coincidence Grouping
Each of the GRC System’s program groups operates with
individual timers and sequences. In order to prevent rappers
within the same precipitator lane to fire together, anticoincidence groups (ACG) must be configured. The GRC
System supports up to 4 ACG’s for each rapper. The figure
below shows an example of a typical precipitator’s anticoincidence group configuration.
Figure 36 - Typical Anti-coincidence Grouping
While the system is operating, the ACG FIFO’s (First In First
Out) can be viewed from the MONITOR window by selecting
ACG FIFO. The indication of “***” next to an anticoincidence group represents an overflow. This occurs when
system timing exceeds the capabilities of the GRC System. See
figure below:
Figure 37 - Anti-Coincidence Window
S-CPU
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Page 57
User Interface
ACG Timers
When the S-CPU detects a conflict between rappers of the same
ACG, it will delay the higher number device by the preset ACG
Time. Typically, this is configured as the amount of time it
takes for fly ash to completely pass through the precipitator. A
value of 0 disables the ACG algorithm. Programmable from 0
to 99 seconds. The ACG time can be set for each of the 5
possible rapper programs saved into the Scpu memory. The
ACG Time for each program, Prg1, Prg2, Prg3, Prg4, and
Prg5 can be changed individually or together as a group by
modifying the Reset parameter.
Rap#
Shows the current rapper number (1 – 1024). Pressing <+Incr>
next/previous set of rapper numbers.
ACG1-4
The four fields to the right of the Rap# represent the anticoincidence group assignments. The GRC System supports up
to 64 ACG’s. Each rapper can be in up to four ACG groups.
Clear-ACG
Selecting this function resets all of the four ACG assignments
(4096) to “0”. Pressing <Enter> will open a dialog box:
“Confirm ACG delete.” “Press enter again to delete”.When
selecting this function a second dialog box appears informing
the user that pressing enter a second time will reset all 4096
ACG assignments to “0”. Pressing any <arrow> key at this
point will prevent the “clearing” of the ACG assignments and
places you back in the ACG screen.
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Page 58
User Interface
Chapter 5: Troubleshooting
Quick determination of rapper controller system problems could
prevent the unfortunate shutdown of the precipitator. The GRC
System provides several tools to assist technicians in
determining the cause of these problems. With a few simple
keystrokes, a complete picture of the system can be retrieved.
The following section describes each of these unique GRC
features.
Figure 38 - Troubleshooting Window
Initiate R-SCAN
Pressing <Enter> on this field will open the R-Scan window and
begin to gather information about the current status of each SRap’s 16 outputs. See R-Scan window shown for more
information.
Figure 39 - R-Scan Window
R-Scan is another of NWL unique GRC system features. This
window allows operators to get operating status for each of the
outputs within seconds. When R-Scan is initiated, the HHP will
instruct each S-Rap module to quickly sample each output and
return the status.
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Page 59
Troubleshooting
The status of each output will be displayed as a single character
(see table below).
Alarm
.
O
U
D
H
S
Description
Device OK
Failed overcurrent test
Failed undercurrent test
Device disabled
Failed half-waving test
Suspect device
Pressing <Enter> on this field will open the window that
displays the rapper currently suspected of causing opacity
spikes. Press <Enter> again to return to the Troubleshooting
menu.
Using the opacity spike detect list, operators can fine tune
rapper operating programs to minimize re-entrainment caused
by specific rappers (see Opacity Spike section in the Monitor
chapter). Verify the Flow Delay and Opacity Spike values are
configured in the S-CPU window for proper operation.
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Page 60
Troubleshooting
Repeat Device(s)
repeating or firing rappers. Either a single rapper or a range of
rappers can be fired with preset settings.
The Repeat Devices window is a useful tool for technicians
when checking the operating status of the GRC System. It can
be used to fire a single device or multiple devices. If the
operator leaves the window before stopping the repeat mode,
the HHP will automatically turn off the repeat mode.
Figure 40 - Repeat Device Window
Lift
This value is used for repeating or firing DC Impact type
devices when repeat mode is enabled. Programmable from 0 to
16 inches in .5 inch steps.
Frq
This value is used for repeating Multi-Impact type devices when
repeat mode is enabled. Programmable in 13 preset steps from
200 to 600 CPM. Valid values are 200, 212, 225, 240, 257,
278, 300, 330, 360, 390, 450, 510, and 600. Press the <+Incr>
or <-Decr> key to scroll through the available settings and press
<Enter> to accept the change.
Int
This value is used for repeating Vibrator and Multi-Impact type
devices. Programmable from 0 to 100%.
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Page 61
Troubleshooting
Dur
This value is used for repeating Vibrator, Multi-Impact, or
Motor type devices. Programmable from 0 to 59 seconds.
Repeat
This field is used for repeating or firing a single device. Select
the device number you wish to energize and use the GO field to
start repeating. Programmable from 0 to 1024.
Repeat .. to ..
These fields are used for assigning a range of devices you wish
to repeat or fire. Set the start and stop device number and select
GO to start energizing devices. The HHP will automatically
step through the devices. After firing the last device, the HHP
will restart at the first device in the list. Programmable from 0
to 1024.
GO
Pressing <Enter> on either of these fields will start the
associated repeat single device or repeat range of devices.
Feedback Gain
Press <+Incr> or <-Decr> to calibrate the lift for DC Impact
type rappers.
STOP
Pressing <Enter> on either of these fields will stop the
associated repeat mode.
Repeat Mode
This field shows the current status of the repeat mode – On or
Off.
Device
This field shows the last device being fired in repeat mode.
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Page 62
Troubleshooting
Current
This field represents the average current (in amperes) of the last
device fired.
Status
This field shows the operating status of the last device fired.
Devices that fail on an alarm condition in repeat mode will not
be removed from normal program firing.
Smart-Rap
This field shows the address of the S-Rap module that contains
the last device fired.
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Page 63
Troubleshooting
Smart System Profile
Within a few seconds, operators can get a “picture” of the
operating status of each of the S-Rap modules. The HHP will
poll each device and display the status in the fields described
below.
Figure 41 - Smart System Profile Window
S-Rap
Shows the address of the associated S-Rap module.
Type
This field shows the current “type” configuration of the
associated S-Rap module. Valid types are “DC Impact”, “AC
Vib(rator)”, “AC/DC Mot(or)”, “Multi-Imp(act)”, “DC
Vib(rator)”, and “POR Outp(ut)”.
Comm
This field indicates whether the associated S-Rap module is
communicating with the HHP.
Version
Software version of each S-RAP in the system will be displayed
in this column.
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Page 64
Troubleshooting
Cal. Stat
Calibration Status of each S-RAP board will be displayed in this
column. Calibration Status can have the following modes:
Normal, Cal, and Failed.
Normal mode means that the S-RAP board successfully
completed Calibration.
Cal mode means that the Calibration is in progress for a
particular S-RAP board.
Failed mode means that the Calibration failed.
Calibration
This feature will be used for DC Impact devices only.
Calibration feature needs to be used if the actual Lift value
measured by the User differs from the programmed Lift value
(due to excessive wiring length or firing non-Research Cottrell
type of rappers). After Calibration is performed the lift accuracy
will be significantly improved.
Calibartion screen is shown below:
Figure 42 - Calibration Window
SRAP:
The User will specify which S-RAP board needs to be
calibrated.
Output…to…
User will specify the range of the outputs that need to be fired to
calibrate the S-RAP.
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Troubleshooting
Low Meas/1/2 cyc:
User will enter the Low number of ½ cycles to fire the
calibrated rapper. The recommended value is 5. The minimal
value is 4.
Low Meas/Action:
User will start/stop the firing of calibrated rapper for Low
number of ½ cycles.
Low Meas/Lift, in:
User will measure the Lift value (in) of the Calibrated rapper
that fires for Low number of half-cycles and enter it into HHP.
High Meas/1/2 cyc:
User will enter the High number of ½ cycles to fire the
calibrated rapper. The recommended value is 10.
High Meas/Action:
User will start/stop the firing of calibrated rapper for High
number of ½ cycles.
High Meas/Lift, in:
User will measure the Lift value (in) of the Calibrated rapper
that fires for High number of half-cycles and enter it into HHP.
Copy from SRAP…to… GO
User will specify the range of S-RAPs to which the Calibration
data will be copied. After the range is specified User will press
GO to initiate the copying of the data.
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Troubleshooting
Save Calibration
Before this new data can be used by the S-RAP board, it must
be saved to Flash memory.
By initiating this option User will save the Calibration data into
the flash memory of the S-RAP board (s). The data will be
saved to all the S-RAP boards that it was copied to.
After this option is selected HHP will prompt the User with the
message: “Burning flash…Please, wait: 2min 30sec” This is
the approximate time it takes for the flash burn. After the
message disappears the User will check if the flash burn was
successful. To do that the User will select Smart System
Profile option from Troubleshoot Menu. Cal. Stat
should indicate Normal if the flash burn was successful.
After Calibration is completed the S-RAP board needs to be
configured to use Calibration Lift Table that was created during
the calibration process.
Please, refer to Ch6. GRC Configuration Summary. Section
Selecting the Lift Table.
REMEMBER: Power must be cycled to the S-RAP board in
order for the S-RAP software to read new switch settings.
Changing Boards
Below is the procedure for replacing the SCPU and the SRAP
boards in the GRC.
SCPU:
It should be noted that the SCPU board contains the memory
where all of the rapping programs are stored. When replacing
this board, the new board will not contain those programs. It is
very important that you save the user programs, ACG data, and
system configuration to the SD card prior to changing the board.
Scroll down to the Sub Menu option in the SCPU screen and
press <Enter>. Scroll down to the SD-CARD FUNCTIONS
and press <Enter>. Back up the user programs, ACG data and
configuration to the SD card.
De-energize the circuit breaker on the GRC cabinet. Loosen the
screws on the bar that hold the boards in the cage captive and
remove the SCPU board. Set the rotary switch of the new
replacement board to the same serial address position as the old
———————————————————————————————————————
Page 67
Troubleshooting
board. Slide the new board into the cage, insuring that the edge
connectors are properly seated in the backplane. Place the SD
card from the old board into the new board.
Energize the cabinet circuit breaker. Return to the SD-Card
Function screen and Load the user programs, ACG data, and
configuration from the SD card back into the SCPU memory.
The board exchange is now complete.
SRAP:
Prior to replacing the SRAP board, scroll to the SRAP screen
and record the parameter settings in the Rapper Setup screen for
the specific SRAP board number being replaced.
De-energize the circuit breaker on the GRC cabinet. Loosen the
screws that hold the boards in the cage captive and remove the
SRAP board. Set the dip switches S1 through S10 of the
replacement board to the same settings as the old board. Slide
the new board into the cage, insuring that the edge connectors
are properly seated in the backplane.
Energize the cabinet circuit breaker. Re-enter all of the
parameters that you recorded from the old board. If you are
operating off of the default lift table, then the board exchange is
complete.
If you are operating off of a user created calibration table, you
may either re-calibrate the SRAP board that was just exchanged
by following the calibration procedure outlined in this User
Guide, or you can copy the calibration from another SRAP
board.
To copy the calibration table from another board, go to the
Calibration screen under the Troubleshooting menu of the HHP
display. Scroll down to the area of the screen that shows “Copy
from SRAP: ___ To: ___ GO”. Enter the SRAP # that you
want to copy the calibration table from and the SRAP# of the
new board you are copying to. Scroll over to the GO and press
the ENTER button on the HHP. The table is now copied to the
new board. But before you can use it, you must first save it to
the flash memory. To do this, scroll down until the “Save
Calibration” is highlighted and press the ENTER button again
———————————————————————————————————————
Page 68
Troubleshooting
on the HHP. The process will begin and a message will be
displayed indicating the status. Once the flash is burned, the
rapper controller can be energized.
.
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Page 69
Troubleshooting
Chapter 6: Configuration Summary
Smart-CPU
4 Character LED Display
RJ45 Jacks
Rotary Selector Switch
Optional Fieldbus Module
Network Port
Local Port
SD Card
Figure 43 - Smart-CPU Board Layout
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Page 70
Configuration Summary
Board Address
The S-CPU modules requires a board address using the
following Rotary Switch settings:
Board Address – Rotary Switch Positions
Switch Position
0 or 1
2
3
4
:
f
Board Address
1
2
3
4
:
15
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Page 71
Smart-Rap
Figure 44 - Smart-Rap Board Layout
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Page 72
Board Address and Rapper outputs range
The S-Rap modules require a board address. It can be
configured using DIP Switch 8. The range of rapper outputs
is assigned to a particular S-Rap address.
Table below links a particular S-Rap address to its
corresponding rapper output range and DIP Switch 8
configuration.
Note: S-Rap board addresses 1…64 are binary 0…63
S-RAP board
address
Rapper outputs
range
Switch 8 position
1 2 3 4 5 6 7 8
1
1-16
x x 0 0 0 0 0 0
2
17-32
x x 0 0 0 0 0 1
3
33-48
x x 0 0 0 0 1 0
4
49-64
x x 0 0 0 0 1 1
5
65-80
x x 0 0 0 1 0 0
6
81-96
x x 0 0 0 1 0 1
7
97-112
x x 0 0 0 1 1 0
8
113-128
x x 0 0 0 1 1 1
9
129-144
x x 0 0 1 0 0 0
10
145-160
x x 0 0 1 0 0 1
11
161-176
x x 0 0 1 0 1 0
12
177-192
x x 0 0 1 0 1 1
13
193-208
x x 0 0 1 1 0 0
14
209-224
x x 0 0 1 1 0 1
15
225-240
x x 0 0 1 1 1 0
16
241-256
x x 0 0 1 1 1 1
17
257-272
x x 0 1 0 0 0 0
18
273-288
x x 0 1 0 0 0 1
19
289-304
x x 0 1 0 0 1 0
20
305-320
x x 0 1 0 0 1 1
21
321-336
x x 0 1 0 1 0 0
22
337-352
x x 0 1 0 1 0 1
23
353-368
x x 0 1 0 1 1 0
24
369-384
x x 0 1 0 1 1 1
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Page 73
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
385-400
401-416
417-432
433-448
449-464
465-480
481-496
497-512
513-528
529-544
545-560
561-576
577-592
593-608
609-624
625-640
641-656
657-672
673-688
689-704
705-720
721-736
737-752
753-768
769-784
785-800
801-816
817-832
833-848
849-864
865-880
881-896
897-912
913-928
929-944
945-960
961-976
977-992
993-1008
1009-1024
1
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
2
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
3
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
6
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
7
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
8
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
———————————————————————————————————————
Page 74
Lift Table Select
Lift Table is used for DC Impact type devices only. There are
two Lift Tables: Default Lift Table and Calibration Lift Table.
S-RAP can be configured to use a certain Lift Table.
This is done by asserting position 1 of the Switch 8.
Switch Setting
0xxxxxxx
1xxxxxxx
Lift Table
Default
Calibration
Stand-Alone Operation
The S-Rap module can be configured to operate in “StandAlone Mode” (without a S-CPU). The following DIP switches
are used for configuring stand-alone operation and the
associated parameters.
Switch 1 - Stand-Alone Operation
Switch Setting
0
1
Description
Disabled
Enabled
Switch 2 - Use Stand-Alone DIPs or Internal Register Values
Switch Setting
0
1
Description
DIPs
Registers
Switches 3, 4, 5 - Initial Wait, Cycle, & Wait Time (x 5
multiplier)
Switch Setting
0000
0001
0010
0011
:
1110
1111
Description
0 minutes
5 minutes
10 minutes
15 minutes
:
70 minutes
75 minutes
———————————————————————————————————————
Page 75
Note: For cycle time only, a setting of 0 seconds represents a 16
second cycle time.
Switch 6 - Device Fire Settings
Switch
Setting
DC
Impact
0
1
Lift
(inches)
4
8
AC/DC Vibrator
& DC MultiImpact
Duration
(seconds)
2
4
AC/DC Motor
Duration
(minutes)
5
Fire All
Continuous
Stand-Alone Operation Defaults
DC Impact
Number of Times in Sequence = 1
AC Vibrator
Intensity = 100%
DC Vibrator
Intensity = 100%
DC Multi-Impact
Intensity = 100%, Frequency = 300 CPM
AC/DC Motor
Intensity = 100%
Device Type
The device type setting is used for determining specific methods
of energizing devices. The following DIP switches must be
setup for each S-Rap module before operation:
Switch 7 - Device Type
Switch Setting
000
001
010
011
100
101
110
Description
120 V Migi
AC Vibrator
AC/DC Motor
DC Multi-Impact
DC Vibrator
T/R POR Outputs
240 V Migi
———————————————————————————————————————
Page 76
Stand-Alone using Internal Registers
The S-Rap module can also be configured using a HHP or PC to
setup registers for the parameters listed below. These values
will be used for Smart System rapping and Stand-Alone rapping
if Switch 2 is set to 1 for “Registers”.
•
•
•
•
•
•
•
Lift (1 - 16 inches) for DC Impact
Intensity (5 - 100%) for AC/DC Vibrators and DC MultiImpact
Frequency (200 - 600 CPM) for DC Multi-Impact
Duration (00:00:01 to 23:59:59 (continuous)) for AC & DC
Vibrators, DC Multi-Impact, and AC/DC Motors
Overcurrent and Undercurrent (amperes) settings for all
types
Enable/Disable status for all types
Alarm relay logic (NO/NC)
Gain Switch
This switch will be set according to the load current range.
If current range is from 0 to 10 Amps then the most accurate
current measurement will be achieved with Gain Switch set to
HIGH position. It could be set to LOW position, but the
accuracy of the current measurement will be lower.
If current range is greater than 0 to 10 Amps then the switch
must be set to LOW position.
Switch S10 – Gain Switch
Gain
Low
High
How to set
Switch moved toward U5 chip
Switch moved away from U5
———————————————————————————————————————
Page 77
System Installation Notes
Connecting RS485 cable between the GRC panels
If the User desires to have a common RS485 communication
line between GRC panels the following procedure should be
followed:
1)
2)
3)
4)
Turn OFF the system Power.
Jumper a shielded communication cable between
2TB-1 inputs of the GRC panels of interest.
Connecting I2C line between GRC panels
I2C line must be common to the GRC panels that
are controlled by a single S-CPU card located on one of
the panels of interest. For example, GRC needs to
control 22 S-RAPs. One panel can contain only one
Card Cage that, in turn, can have 11 S-RAPs. Therefore,
2 panels are needed for the system.
S-RAPs 1 through 11 will contain outputs 1-176;
S-RAPs 12 through 22 will contain outputs 177-352.
In order for this system to operate I2C line must be
common to both panels. To connect I2C lines the
following steps should be taken:
1)
2)
3)
4)
Turn OFF the system Power.
Jumper TB4-1 terminals of the Backplanes
located on GRC panels of interest.
———————————————————————————————————————
Page 78
Glossary of Terms
ACG
Anti-Coincidence Groups – A collection or group of assigned rappers to prevent rapping along the
gas-flow of the precipitator. ACG’s are used to minimize re-entrainment.
DIP Switch
Dual Inline Package – Printed circuit board level switches used for configuration.
ESP
Electrostatic Precipitator – Pollution control device that utilizes electrostatic charges for fly-ash
collection.
FIFO
First In First Out – Term used in the technology industry to represent a list where the first device
entered into the list will be the first device removed.
Flash Memory
High-speed non-volatile memory used for storage on computer, electronic controls, etc.
Fly-ash
Output of burned coal from the plant’s boiler that enters the precipitator for collection.
GRC
Graphic Rapper Controller – NWL’s next generation rapper controller that uses a graphical display.
HHP
Hand Held Programmer – NWL’s GRC System programming device.
NVRAM
Non-volatile Random Access Memory – Memory used on computers, electronic controls, etc. that
will retain the contents in the event of power loss.
———————————————————————————————————————
Page 79
Glossary of Terms
POR
Power Off Rapping – A technique used for more effective collection plate cleaning where the power
is removed or reduced from a field before rapping occurs.
Rapper
Generic name for a device that “raps” a precipitator collection plate or electrode wire for cleaning
purposes.
Re-entrainment
Fly ash that re-enters that gas stream after being collected. Typically caused from excessive rapping.
Rip/Rap
NWL’s unique method for minimizing re-entrainment where rappers are fired with multiple impacts
with increasing energy.
S-CPU
NWL’s Smart-CPU module responsible for scheduling rapper activity.
S-Rap
NWL’s Smart-Rap module responsible for energizing rapper devices and monitoring for alarm
conditions.
———————————————————————————————————————
Page 80
Glossary of Terms
Appendix 1 – Fieldbus Data Exchange Map
NWL S-CPU Network Data Exchange Map - Rev. 0.4
Date: 6/13/2014
Web
Idx #
Parameter
Data
Bit Assignments Data Type Instance #
Min
Value
Max
Value
Modbus
Register #
Default (Anybus-CC
Value and Net Port)
Modbus
Register #
(Net Port
only)
PROFIBUS
DP/V1
Acyclic - Slot
#
PROFIBUS
DP/V1
Acyclic Index
0
0
Notes
Process READ Data (Data Read from NWL Controller)
1
Controller Status
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
2
3
4
5
6
7
8
9
10
11
12
Active Operating Program
Remote Software Select
Active Rapper 1
Active Rapper 2
Active Rapper 3
Active Rapper 4
Active Rapper 5
Active Rapper 6
Average Opacity
Average Boiler Load
SRAP1-SRAP16 Alarms
Bit
Bit
13
14
15
16
SRAP17-SRAP32 Alarms
SRAP1-SRAP16 Comm Failures
Bit
Bit
17
18
19
UINT16
1
15 - POR Mode MSB
14 - POR Mode LSB
13 - Spare
12 - Spare
11 - Spare
10 - Spare
9 - Spare
8 - Auto Program Select Enabled
7 - Program Restart Mode Enabled
6 - Local Remote Input State
5 - Remote Program On Input State
4 - POR Program On
3 - S-RAP Comm Error(s)
2 - S-RAP Alarm(s)
1 - Program On
0 - 1 Sec Heartbeat toggle
UINT16
2
UINT16
3
UINT16
4
UINT16
5
UINT16
6
UINT16
7
UINT16
8
UINT16
9
UINT16
10
UINT16
11
UINT16
12
15 - SRAP16 Alarmed
…
0 - SRAP1 Alarmed
UINT16
13
UINT16
14
UINT16
15
UINT16
16
15 - SRAP16 Comm Fail
…
0 - SRAP1 Comm Fail
UINT16
17
UINT16
18
UINT16
19
30001
0=Off, 1=Local, 2=Remote
0
0
0
0
0
0
0
0
0
0
5
2
1024
1024
1024
1024
1024
1024
999
9999
30002
30003
30004
30005
30006
30007
30008
30009
30010
30011
30012
0
0
0
0
0
0
0
0
0
0
0
1
2
3
4
5
6
7
8
9
10
11
30013
30014
30015
30016
0
0
0
0
12
13
14
15
30017
30018
30019
0
0
0
16
17
18
———————————————————————————————————————
0=Disable, 1=Discrete, 2=Network
0=No activity, 1…1024=Device Number
Page 81
Web
Idx #
Parameter
Data
Modbus
Register #
Default (Anybus-CC
Value and Net Port)
Modbus
Register #
(Net Port
only)
PROFIBUS
DP/V1
Acyclic - Slot
#
PROFIBUS
DP/V1
Acyclic Index
Min
Value
Max
Value
0
1
0
1
5
2
0
1
0
40628
40629
40630
40001
40002
40003
0
0
0
99
100
101
Notes
Process WRITE Data (Data Written to NWL Controller)
20
21
22
Operating/POR Program: On/Off
Active Operating Program
POR Mode
UINT16
UINT16
UINT16
100
101
102
0=Off, 1=On
0=Off, 1=Local, 2=Remote
Application Data Instances (ADIs) Accessible via Acyclic Messaging Only
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Software Version ID
Program Restart Mode
Alarm Relay Logic
# of Alarms Before Activating Relay
Boiler Load Full Scale
System Clock Set - Month
System Clock Set - Day
System Clock Set - Year
System Clock Set - Hour
System Clock Set - Min
System Clock Set - Sec
Auto-Program Select On/Off Switch
Auto-Program by Load - Step 1 Min
Load
Auto-Program by Load - Step 1 Max
Load
Auto-Program by Load - Step 1
Program #
Load
Load
Program #
Load
Load
Program #
Auto-Program by Time - Step 1 Min
Time Hours
Time Minutes
Time Seconds
Auto-Program by Time - Step 1 Max
Time Hours
Time Minutes
Time Seconds
Auto-Program by Time - Step 1
Program #
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
UINT16
103
104
105
106
107
108
109
110
111
112
113
114
0
0
0
1
0
1
1
0
0
0
0
0
9999
1
1
99
9999
12
31
99
23
59
59
1
R/O
0
0
1
1000
1
1
13
0
0
0
0
40631
40632
40633
40634
40635
40636
40637
40638
40639
40640
40641
40642
40004
40005
40006
40007
40008
40009
40010
40011
40012
40013
40014
40015
0
0
0
0
0
0
0
0
0
0
0
0
102
103
104
105
106
107
108
109
110
111
112
113
UINT16
115
0
9999
0
40643
40016
0
114
UINT16
116
0
9999
0
40644
40017
0
115
UINT16
117
0
5
0
40645
40018
0
116
UINT16
118
0
9999
0
40646
40019
0
117
UINT16
119
0
9999
0
40647
40020
0
118
UINT16
120
0
5
0
40648
40021
0
119
UINT16
121
0
9999
0
40649
40022
0
120
UINT16
122
0
9999
0
40650
40023
0
121
UINT16
123
0
5
0
40651
40024
0
122
UINT16
124
0
23
0
40652
40025
0
123
UINT16
125
0
59
0
40653
40026
0
124
UINT16
126
0
59
0
40654
40027
0
125
UINT16
127
0
23
0
40655
40028
0
126
UINT16
128
0
59
0
40656
40029
0
127
UINT16
129
0
59
0
40657
40030
0
128
UINT16
130
0
5
0
40658
40031
0
129
———————————————————————————————————————
0=Continue, 1=Restart
0=Normally Open, 1=Normally Closed
System clock is updated when "Seconds"
registers is written.
0=Auto-Program Select disabled
Page 82
Web
Idx #
65
66
Parameter
Time Hours
Time Minutes
Time Seconds
Time Hours
Time Minutes
Time Seconds
Program #
Time Hours
Time Minutes
Time Seconds
Time Hours
Time Minutes
Time Seconds
Program #
Auto-Program Default Program
Global Anti-Coincidence Time Set
67
51
52
53
54
55
56
57
58
59
60
61
62
63
64
Data
Min
Value
Max
Value
Modbus
Register #
Default (Anybus-CC
Value and Net Port)
Modbus
Register #
(Net Port
only)
PROFIBUS
DP/V1
Acyclic - Slot
#
PROFIBUS
DP/V1
Acyclic Index
UINT16
131
0
23
0
40659
40032
0
130
UINT16
132
0
59
0
40660
40033
0
131
UINT16
133
0
59
0
40661
40034
0
132
UINT16
134
0
23
0
40662
40035
0
133
UINT16
135
0
59
0
40663
40036
0
134
UINT16
136
0
59
0
40664
40037
0
135
UINT16
137
0
5
0
40665
40038
0
136
UINT16
138
0
23
0
40666
40039
0
137
UINT16
139
0
59
0
40667
40040
0
138
UINT16
140
0
59
0
40668
40041
0
139
UINT16
141
0
23
0
40669
40042
0
140
UINT16
142
0
59
0
40670
40043
0
141
UINT16
143
0
59
0
40671
40044
0
142
UINT16
144
0
5
0
40672
40045
0
143
UINT16
UINT16
145
146
0
0
5
99
0
0
40673
40674
40046
40047
0
0
144
145
Anti-Coincidence Time for Program 1
UINT16
147
0
99
0
40675
40048
0
146
68
UINT16
148
0
99
0
40676
40049
0
147
69
UINT16
149
0
99
0
40677
40050
0
148
70
UINT16
150
0
99
0
40678
40051
0
149
71
UINT16
151
0
99
0
40679
40052
0
150
72
Clear Output Alarms
UINT16
152
1
9999
0
40680
40053
0
151
———————————————————————————————————————
Notes
Sets all programs' ACG timers to sent value
Write output number to this register to clear
alarms (e.g., write 5 to clear output 5 alarms).
Write 9999 to clear all active alarms.
Page 83
Web
Idx #
73
Parameter
Output Status: Devices 1-4
74
75
Data
UINT16
153
Bits 15...12 - Output 4 Status
Bits 11…8 - Output 3 Status
UINT16
UINT16
154
155
Modbus
Register #
Default (Anybus-CC
Value and Net Port)
R/O
40681
Modbus
Register #
(Net Port
only)
40054
PROFIBUS
DP/V1
Acyclic - Slot
#
0
PROFIBUS
DP/V1
Acyclic Index
152
Min
Value
0
Max
Value
65535
0
0
65535
65535
R/O
R/O
40682
40683
40055
40056
0
0
153
154
65535
65535
65535
65535
R/O
R/O
R/O
R/O
40782
40783
40784
40785
40155
40156
40157
40158
0
0
1
1
253
254
0
1
65535
R/O
40936
40309
1
152
Notes
Each output status is represented by 4 bits in
these registers, as follows:
0=Output Disabled
1=Output OK (no errors)
2=Undercurrent
3=Overcurrent
4=Half-wave
5=Suspect UC
6=Suspect OC
7=Suspect Half-wave
…
174
175
176
177
Output
Output
Output
Output
Status:
Status:
Status:
Status:
Devices
Devices
Devices
Devices
405-408
409-412
413-416
417-420
UINT16
UINT16
UINT16
UINT16
254
255
256
257
0
0
0
0
…
328
UINT16
408
0
———————————————————————————————————————
Page 84
Appendix 2 – Fieldbus Module Additional Information
For Fieldbus modules that utilize a Ethernet style RJ45 jack (Ethernet IP, Modbus TCP,
ProfiNet, etc.) :
———————————————————————————————————————
Page 85
For Fieldbus modules that utilize a 9 pin D connector (Modbus RTU, Profibus DPV1, etc.) :
———————————————————————————————————————
Page 86
For DeviceNet Fieldbus Module :
———————————————————————————————————————
Page 87
Additional information on the fieldbus modules can be obtained from the manufacturer at
www.anybus.com
———————————————————————————————————————
Page 88
Appendix 3 – DSP Board Four Character LED Display Messages
Message Types
The 4-character display messages are classified as either "short" (4 characters or less) or "long" (more
than 4 characters) messages.
The short messages are displayed for 2 seconds without scrolling. The long messages are scrolled
once (with 250 ms per character scrolling rate).
When multiple event messages are pending in display message queue (see "Events" section below),
the display sequence is accelerated as follows: short messages are only shown for 1 second, and long
messages are scrolled twice as fast (125 ms per character rate). The maximum queue size is 4
messages, and if events occur quickly, the oldest ones will be "kicked out" from the queue (i.e., they
will never be displayed).
Normal Operation
During normal operation, the 4-character display on the DSP board cycles through the following
messages:
Message
"Program: X"
Description
Shows current operating program number, or "idle" if operating program
is off.
"S-RAP: ok"
Current status of S-RAP cards in the system. "alarmed" means that at least
"S-RAP: alarmed"
one S-RAP card has an output in alarmed state. "comm fail" means that at
"S-RAP: comm fail"
least one S-RAP card is not communicating with S-CPU.
"S-RAP: alm/comm fail"
Displays opacity measurement (moving average). This is the value
"Opacity: xx.x%"
reported via RS485. A "faster" average is used for opacity spike detection.
Displays boiler load measurement (moving average). This is the value
"Boiler Load: x"
reported via RS485.
Additionally, the following messages will be shown continuously when S-CPU is performing a timeconsuming operation:
Message
"busy"
"Programming Mode"
Description
S-CPU is writing or reading files on the SD card.
Operating programs are being read or written by Handheld Programmer.
———————————————————————————————————————
Page 89
Events
At any time if an event occurs that needs to be displayed to the user, the normal display sequence
described above will be interrupted and the event message will be displayed immediately.
Event messages:
Message
"S-CPU Vx.xx"
"Default settings"
"Warm"
"Program ON"
"Program OFF"
"No SD card"
"SD config saved"
"SD config restored"
"SD programs saved"
"SD programs loaded"
"Saved ACG config"
"Loaded ACG config"
Description
S-CPU firmware version. Displayed after power-up.
Default S-CPU settings are loaded, either because NVRAM check failed
after power-up, or requested by user.
"Warm" reset occurred (as opposed to a "cold" reset due to a power cycle).
Operating program is turned on via RS485, fieldbus, or discrete input.
Operating program is turned off via RS485, fieldbus, or discrete input.
Displayed when an SD card operation is requested by user, but SD card is
not present.
S-CPU configuration has been written to SD card.
S-CPU configuration has been read from SD card and applied.
S-CPU programs have been saved to SD card.
S-CPU programs have been read from SD card into S-CPU's non-volatile
memory.
Anti-Coincidence Group (ACG) configuration has been saved to SD card.
Anti-Coincidence Group (ACG) configuration has been read from SD card
into S-CPU's non-volatile memory.
14 Mar 2014
———————————————————————————————————————
Page 90

Graphic Rapper Controller™ (GRC) User`s Guide

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